Build Session 23 (240 mins): Shaping the Adapter Plate

I decided to hold off on the dual motor setup for now in hopes of getting this truck up and running this year.

This weekend Jared, Chad, and I marked and cut the 1/2 inch adapter plate that connects the transmission bell housing to the motor adapter.

We used the Rigid band saw with a 3/4 inch Lenox Bi-Metal blade and a LOT of aluminum cutting oil. The cutting was slow going but the end result was worth it. After cutting we cleaned up the edges with the grinder, wire wheel, and a little filing. During the next build session we will drill the holes and bolt the bell housing to the adapter plate.

The adapter plate before we cut...

Clamping the plate down and then tracing the bell housing...

 

 The cutting is slow...Chad keeps the blade plenty lubed with aluminum cutting oil which definitely saved the blade.

  

 We used to brush to keep the oil where we wanted it...

  

 Still cutting hours later...

  

   

Pretty good for a 3/4 inch band saw blade...

  

I'm grinding down the rough cuts... 

  

  

Chad decided to hand file a bit.

  

  

Perfect fit...I like it. Its ready for drilling during the next build session.

 

Build Session 21 (180 mins): Epoxy Painted Battery Racks and Frame

This weekend Jared, Chad, and I had a productive painting session. In a couple of hours we managed to finish the welding on the rear battery racks. Then we painted the rear battery racks, rear differential, and frame with POR-15 Epoxy paint which should keep them from rusting.

Jared and my welding helmets.

Jared and Chad painting. Chad is a good friend of ours. He just graduated from High School, is an invaluable robotics club member on the team that we mentored and is a skilled machinist. Not bad for a teenager!

Starting from the inside and working our way out...

Remember how many months ago we spent a whole day prepping the frame with scrub brushes and the pressure washer...I think it was about a year ago. Wow, time fly's.

I even painted the frame underneath after laying out plastic on the driveway an taping plastic around the cab.

The epoxy paint goes a long ways and looks great.

Nice...

It looks amazing!

Chad got some POR-15 epoxy on himself...It should wear off in a few weeks. Sorry Chad. :)

Adapter plate is here...

A couple of weeks ago I sent the clutch disc from my S-10 (actually I ordered a new one and sent that) to a machine shop specified by EV-America. They disassembled the disc and  milled out the a the center portion of the adaptor plate assembly from 1/2 inch 6061 aluminum. In the near future I will attach this plate to my S-10 transmission, take some measurements, and then mill the transmission mating holes for attaching the plate. Then I plan to cut down the excess around the corner and perhaps follow the contours of the transmission bell housing. After that I will attach the Advanced DC 9 inch FB1 electric motor to the adaptor plate and transmission.

Build Session 16 (90 mins): Rear Battery Rack Welding Cross Member

Yes, I'm still working on the rear battery rack. :) One more day and I should have the rear rack finished.

First I prepped the flat bar cross member that I bent yesterday. I'm using the wire attachment on the Makita to remove the rust.

Prepping the frame...

Measuring the distance at the top of the new cross member to make sure that its slightly more (1/2 inch) than the 31 inches at the bottom of the cross member. This will allow the battery box to slide in easier. The cross member is clamped into place and I tapped it into position with a hammer.

Then I welded the cross member into place.

In case you're wonder what welder I'm using...

It's a Lincoln Power Mig 140c Welder. I'm not using MIG right now just .035 inch Flux Core Welding Wire and it seems to be working great for this application. The bottle on the back of the welder currently is Argon which I use when I am welding aluminum. I use argon with the spool gun pictured below.

.035 inch Flux Core Welding Wire

100 SG spool gun used for welding aluminum and other types of metal.

Anyway, back to business here...Then I wire brushed the area where the flat bar cross member supports meet, clamped them together, and welded all three of them in place. That's it for tonight.

Build Session 15 (45 mins): Rear Battery Rack Cross Member Bending

Not much time again tonight...but it was enough to cut and bend a piece of 3 inch flat bar for the rear battery box rack. This piece will provide cross support for the rear battery rack. The flat bar is 1/4 inch thick. I cut it 68 inches which turns out to be a 1/2 inch or so to long (I'll fix that tomorrow when I weld it in place).

I convinced my oldest son Matt to step away from his laptop long enough to work square up this piece and help me bend it.

Using the torch to heat the steel...

Matt is learning how to use the torch...he did a great job!

Me...trimming the acetylene...

Preparing for the third bend...

Not much leverage so Matt used the sledge on this bend...

The new 3 inch cross bar sitting in place... I plan to trim the ends down an inch and weld it in place tomorrow.

A video of Matt using the torch.

Build Session 14 (30 mins): Battery Rack Build Session 7

Tonight I cut (most of) the rear support section out of the Chevy S10 frame. This piece needs to be removed to make room for the polyurethane battery boxes that I will build in the near future. That sums up my accomplishments for this weekend as I am camping with the family at Whidbey Island.

Using the Makita with a cut-off wheel...

Support section removed...

I plan to remove the rest of this support section after completing the rear battery rack and adding additional support to the shock mounts.

Build Session 13 (1 hour): Rear Battery Rack Welding

Back from San Diego and ready to work on the truck...

I did get three of the support bars welded into the rear battery rack tonight.

Of course I wouldn't have been able to do it as fast without a little help from Tayler.


We clamped the "U" shaped pieces into place and squared and welded them to the support tubes (one side at a time).

Notice the surface rust building up already...don't worry, my POR15 chassis coat epoxy showed up last week. As soon as these battery racks are done I will prep and paint. :)


Tayler with a wire brush...I wish that I could get her to scrub the dishes this good. :)


Using the Makita wire brush to clean up my welds.


Three pieces welded in place. In my next session I will build 3 additional pieces to complete this rear battery rack.



The POR15 showed up! This will protect the frame and battery racks...plus it will look great.